Head-up display with a segmented cover

Abstract

A head-up display unit having a segmented cover includes a housing having an upper surface defining an aperture to an interior space and holding a combiner. The combiner is movable between a storage position within the housing and an operational position extending through the aperture. The segmented cover is movable between a closed position covering the aperture and an opened position uncovering the aperture. The segmented cover includes a plurality of flaps of rigid material, each having a generally rectangular elongated profile and arranged adjacent and parallel to one another. The segmented cover also includes a flexible connection between adjacent ones one of the flaps to allow the segmented cover to be rolled cylindrically into the opened position. The flexible connection includes flexible material overmolded on the flaps in one or more different configurations. A method of constructing the segmented cover for a head-up display unit is also provided.

What is claimed is: 
     
         1 . A head-up display unit having a segmented cover and comprising:
 a housing having an upper surface defining an aperture to an interior space and holding a combiner;   the segmented cover movable between a closed position covering the aperture and an opened position uncovering the aperture to allow the combiner to protrude therethrough;   the segmented cover including a plurality of flaps of rigid material each having a generally rectangular elongated profile and a generally rectangular cross-section, and with the flaps being disposed adjacent and parallel to one another;   a flexible connection between adjacent ones of the flaps to allow the segmented cover to be rolled cylindrically into the opened position;   the flaps of the segmented cover defining an inner surface facing the interior space of the housing with the segmented cover in the closed position and defining an outer surface opposite the inner surface.   
     
     
         2 . The head up display unit having a segmented cover as set forth in  claim 1 , wherein the flexible connection includes a first layer of flexible material affixed to the outer surface of the flaps and defining a smooth exterior surface of the segmented cover. 
     
     
         3 . The head-up display unit having a segmented cover as set forth in  claim 2 , wherein the first layer of flexible material is overmolded onto the outer surface of the flaps. 
     
     
         4 . The head-up display unit having a segmented cover as set forth in  claim 1 , wherein the flexible connection includes a second layer of flexible material affixed to the inner surface of the flaps. 
     
     
         5 . The head-up display unit having a segmented cover as set forth in  claim 4 , wherein the second layer of flexible material is overmolded onto the inner surface of the flaps. 
     
     
         6 . The head-up display unit having a segmented cover as set forth in  claim 1 , wherein the inner surface each of the plurality of flaps includes a rib extending transversely therefrom. 
     
     
         7 . The head-up display unit having a segmented cover as set forth in  claim 1 , wherein the ribs are integrally formed with the flaps of rigid material. 
     
     
         8 . The head-up display unit having a segmented cover as set forth in  claim 1 , wherein the flexible connection includes a webbing of flexible material affixed between adjacent ones of the flaps. 
     
     
         9 . The head-up display unit having a segmented cover as set forth in  claim 8 , wherein the webbing of flexible material is overmolded between adjacent ones of the flaps of the segmented cover. 
     
     
         10 . The head-up display unit having a segmented cover as set forth in  claim 8  wherein the webbing of flexible material does not contact the inner surface or the outer surface of the flaps. 
     
     
         11 . The head-up display unit having a segmented cover as set forth in  claim 1 , wherein the combiner is movable between a storage position within the housing and an operational position extending through the aperture. 
     
     
         12 . The head-up display unit having a segmented cover as set forth in  claim 1 , further including an opening mechanism to move the segmented cover from the closed position to the opened position. 
     
     
         13 . The head-up display unit having a segmented cover as set forth in  claim 12 , wherein the opening mechanism includes a first spool attached to a first end of the segmented cover for pulling the segmented cover to the opened position. 
     
     
         14 . The head-up display unit having a segmented cover as set forth in  claim 1 , further including a closing mechanism to move the segmented cover to the closed position. 
     
     
         15 . The head-up display unit having a segmented cover as set forth in  claim 14 , wherein the closing mechanism includes a second spool attached to a second end of the segmented cover for pulling the segmented cover to the opened position. 
     
     
         16 . A method of constructing a segmented cover for a head-up display unit comprising:
 molding a plurality of flaps of a rigid material, with each of the flaps having a generally rectangular elongated shape;   aligning the plurality of flaps parallel to one another;   overmolding a flexible material on the plurality of flaps to form a flexible connection between adjacent ones of the flaps;   removing the plurality of flaps from the overmolding as a segmented cover; and   mounting the segmented cover to a housing of the head-up display unit.   
     
     
         17 . The method of constructing a segmented cover for a head-up display unit as set forth in  claim 16 , wherein each of the flaps has a generally rectangular cross-section defining an inner surface and an outer surface opposite thereof; and
 wherein the step of overmolding a flexible material on the plurality of flaps to form a flexible connection between adjacent ones of the flaps includes affixing the flexible material on the outer surface of the flaps.   
     
     
         18 . The method of constructing a segmented cover for a head-up display unit as set forth in  claim 16 , wherein each of the flaps has a generally rectangular cross-section defining an inner surface and an outer surface opposite thereof; and
 wherein the step of overmolding a flexible material on the plurality of flaps to form a flexible connection between adjacent ones of the flaps includes affixing the flexible material on the inner surface of the flaps.   
     
     
         19 . The method of constructing a segmented cover for a head-up display unit as set forth in  claim 16 , wherein each of the flaps has a generally rectangular cross-section defining an inner surface and an outer surface opposite thereof; and
 wherein each of the flaps includes a rib extending generally transversely from the inner surface; and   wherein the step of overmolding a flexible material on the plurality of flaps to form a flexible connection between adjacent ones of the flaps includes affixing the flexible material on the inner surface of the flaps and between the ribs thereof.   
     
     
         20 . The method of constructing a segmented cover for a head-up display unit as set forth in  claim 16 , wherein each of the flaps has a generally rectangular cross-section defining an inner surface and an outer surface opposite thereof and two sides extending between the inner surface and the outer surface; and
 wherein the step of overmolding a flexible material on the plurality of flaps to form a flexible connection between adjacent ones of the flaps includes affixing the flexible material between the sides of the flaps.